Roof Repair With Solar Panels: How to Restore Roofing Under Photovoltaic Systems

Repairing a roof with solar panels involves navigating mounting hardware, electrical components, and warranty questions while ensuring watertight results and system safety. This guide explains the process, options, costs, and best practices to minimize risk and downtime when homeowners or contractors address roof damage with an existing solar array.

Issue	Key Consideration	Typical Action
Shingle Damage	Fastener Penetrations Under Racking	Remove panels, replace shingles, reseal penetrations
Flashing Leaks	Rails Near Roof Intersections	Replace/upgrade flashing and underlayment
Sagging Roof	Structural Load + Age	Structural repair or partial re-roof with panel reinstallation
Warranty Impact	Manufacturer/Installer Policies	Coordinate with installer before work

Solar installations can both cause and conceal common roofing issues. Penetration leaks, compromised flashing, and trapped moisture under rails are leading causes of post-installation leaks. Conversely, panels can mask damaged shingles or rot that becomes evident only when panels are removed.

• Penetration And Flashing Failures: Roof mounts and lag bolts can fail or be improperly sealed.
• Hidden Deck Rot: Extended panel coverage delays detection of underlayment or decking failures.
• Improper Air Flow And Moisture Buildup: Poor racking clearance can trap heat and moisture.
• Structural Stress: Older roofs may show sagging under the combined load of roofing materials and PV arrays.

Assessing The Roof And Solar System Before Repair

Thorough assessment should include an exterior roof inspection, attic inspection for moisture or rot, and a solar system review for mount locations and wiring. Document mount types, flashing details, and the inverter/combiner locations so repair planning minimizes surprises during work.

Inspection Checklist

• Identify all roof penetrations related to mounts, conduit and cable entries.
• Check under-array ventilation and signs of trapped moisture or mold.
• Confirm rafter, truss, and decking condition in attic and at visible mounts.
• Review original solar installation drawings or photos if available.

Coordinating With Solar Installers And Warranty Holders

Before any roof work, contact the solar installer and check equipment and roofing warranties. Many solar installers require authorized technicians for panel removal/reinstallation to protect electrical warranties, and roofers may require written permission to work around PV components.

Questions To Ask

• Does the solar installer include panel removal and reinstallation in their contract or warranty?
• Will the panel manufacturer void warranties if untrained personnel disconnect modules?
• Are there documented procedures for working on the array to maintain NEC and local code compliance?

Options For Roof Repair With Solar Panels In Place

There are multiple approaches depending on repair scope: working around the array, partial panel removal, or full system removal. Choosing the right option balances cost, risk to the solar system, and long-term roof integrity.

Working Around The Array

This minimal-intrusion method addresses localized repairs without moving panels. It works for small leaks away from mounts but may require rooftop staging and careful flashing work to avoid disturbing modules. Use this only when mount locations are not affected and access is safe.

Partial Panel Removal

Removing a section of panels gives access to a larger work area while keeping much of the array energized or in place. Partial removal reduces reinstall labor and often suffices for mid-sized repairs like replacing multiple shingles or flashing.

Full System Removal

Full removal is necessary for a complete re-roof or when the deck is compromised. Although the most disruptive and costly, full removal ensures complete access for durable repairs and allows for replacement of underlayment and flashing.

Safety And Code Compliance During Repairs

Roof repairs with solar present electrical and fall hazards. Always follow NEC (National Electrical Code), OSHA fall protection standards, and local building codes. Qualified electricians should handle PV disconnects and reconnections; roofers must use fall protection and trained panel-handling procedures.

Key Safety Steps

• De-energize the PV array if panels will be removed or wiring disturbed.
• Use lockout/tagout and communicate roles between roofers and electricians.
• Provide fall protection and safe access for personnel working around arrays.

Material Choices And Techniques For A Durable Repair

Choosing high-quality underlayment, flashing, and sealants is critical where solar mounts penetrate the roof. Use self-sealing flashing, synthetic underlayments rated for PV use, and corrosion-resistant mount hardware to extend service life and reduce callbacks.

• Upgrade to a synthetic breathable underlayment compatible with PV mounting systems.
• Install proprietary flashing designed for solar mounts where available.
• Use closed-cell foam or OEM gaskets on mount penetrations instead of generic caulk for long-term sealing.

Cost Factors And Typical Pricing Ranges

Costs vary widely by repair scope: small localized repairs around panels are lower, while full system removal and re-roofing are significantly higher. Expect labor premiums when coordination with electricians or solar installers is required.

Repair Type	Typical Cost Range
Localized Shingle/Flashing Repair	$250–$1,000
Partial Panel Removal + Repair	$1,000–$5,000
Full Solar Removal And Reinstall (with Re-Roof)	$3,000–$15,000+ depending on array size

Scheduling Repairs To Minimize Downtime And Risk

Plan roof work during favorable weather and coordinate panel removal times to keep system downtime minimal. Provide the solar installer with at least a few days’ notice and schedule electricians and roofers sequentially to speed the process.

Best Practices

• Arrange a pre-job meeting with roofer, electrician, and solar installer to review scope and responsibilities.
• Document the array condition with photos before removal and after reinstallation.
• Test the PV system after reinstallation and verify microinverter/string inverter performance.

When To Consider Upgrading The Solar Mounting Or System During Repair

Roof repair is an opportunity to improve PV integration. Upgrading to rail-less mounts, corrosion-resistant hardware, or relocating modules for better access can reduce future maintenance risk. Consider upgrades when panels are already removed for a re-roof to avoid repeat labor.

Upgrade Options

• Rail-Less Mount Systems To Reduce Penetrations
• Integrated Flashing Or Non-Penetrating Ballasted Systems Where Appropriate
• Relocation Of Junction Boxes For Easier Future Access

Finding Qualified Contractors And Verifying Experience

Select contractors experienced in both roofing and PV systems or ensure strong coordination between specialists. Look for roofers with documented solar project experience and solar installers who work closely with local roofers to avoid blame-shifting and warranty conflicts.

Verification Steps

• Request references from similar projects with photos and scope descriptions.
• Verify licenses, insurance, and bonding for both roofing and electrical work.
• Obtain a coordinated contract clarifying which party handles panel removal, flashing, and warranty communication.

Case Study: Typical Full Re-Roof With Solar Reinstallation

A mid-size home required deck replacement and full underlayment upgrade. The installer removed the 20-panel array, a roofer replaced decking and synthetic underlayment, and flashing was upgraded around all mounts. Reinstallation included upgraded racking and a performance test, resulting in a watertight roof and restored PV output.

Task	Time	Notes
Panel Removal	6–8 Hours	Performed By Certified Installer
Roof Decking & Underlayment	1–2 Days	Includes New Flashing
Panel Reinstall And Testing	6–8 Hours	Includes Electrical Checks

Key Takeaways For Homeowners Considering Roof Repair With Solar Panels

Planning, coordination, and using qualified professionals are essential to protect both the roof and solar investment. Document conditions, confirm warranty requirements, and consider upgrades when panels are removed to maximize long-term value.

For complex repairs or full re-roofs, budget for potential solar removal and involve the solar installer early to ensure a safe, code-compliant, and durable outcome.